Packaging Machine Heater Fault Detection by Power Normalization
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for determining the functionality of heating devices in packaging machines are prone to inaccuracies due to defective heating elements, leading to incorrect assessments and potential operational risks.
Innovation Solution
A method and detection system that involves determining the current heating output, normalizing it, comparing it to a theoretical output, and generating status signals to ensure accurate operation, and outputting a status signal to address the functionality of the heating device, including a determination unit, normalization unit, comparison unit, and output unit.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If heating power or heating current of individual heating elements is measured and summed to form a reference value, then the functionality determination process is simple, but the measurement precision deteriorates because a defective heating element leads to incorrect reference value and incorrect functionality assessment
Solution Approach 1:
The patent divides the heating device into individual heating elements and evaluates each element's functionality separately by comparing its current heating output against its specific theoretical heating output, rather than aggregating all elements into a single reference value. This segmentation allows defective elements to be identified individually without compromising the overall assessment accuracy.
Solution Approach 2:
Instead of determining functionality by summing heating powers or currents (aggregate approach), the patent inverts the approach by evaluating each heating element independently and then determining overall functionality based on individual element assessments. This inversion prevents defective elements from skewing the reference value and enabling accurate functionality determination.
2Productivity
If a defective heating element is not detected, then the heating device can continue to operate, but reliability deteriorates because the defective element compromises heating performance and product quality
Solution Approach 1:
The patent performs preliminary functionality checks by comparing current heating output against theoretical heating output before the heating device is used for production. This preliminary detection identifies defective heating elements in advance, allowing them to be replaced or repaired before they compromise product quality or cause production issues.
Solution Approach 2:
The patent establishes a feedback mechanism where the current heating output of each heating element is continuously monitored and compared against its theoretical heating output. When a deviation is detected indicating a defective element, the system provides feedback that triggers an alert or shutdown, preventing continued operation with defective elements and maintaining reliability.
3Measurement precision
If normalization of heating output is performed, then the measurement precision improves by enabling accurate comparison, but the device complexity increases due to additional processing steps
Solution Approach 1:
The patent transforms the heating output parameter by normalizing it against the theoretical heating output for each individual heating element. This parameter change converts absolute heating power values into relative performance ratios, enabling accurate comparison between current and expected performance while accounting for variations in heating element specifications and operating conditions.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures a reliable and simple determination of heating device functionality, preventing operation with defects, improving safety, maintenance, and product quality, and reducing waste.
Implementation Method 1
The current heating power is measured with at least one sensor, or the current machine current and voltage of the heating device are measured with at least one sensor
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
A method (60) for determining the functionality of a heating device (25, 25') with at least one heating element (36, 37, 38, 39, 40) for a packaging machine (1) comprises the following steps: determining an actual heating power (PM) of the heating device (25, 25') using a determination unit (29), determining a normalized actual heating power (PTN(actual)) based on the actual heating power (PM) using a normalization unit (30), determining a deviation (50) of the normalized actual heating power (PTN(actual)) from a normalized theoretical heating power PTN(theoretical) using a comparison unit (31), determining a status signal (52, 53) about the functionality based on the deviation (50) using a selection unit (32), and outputting the status signal (52, 53) using an output unit (33).